SPE-185275-MS

Design, Operation, Diagnosis, Failure Analysis and Optimization of ESP

Systems in Wells with Great Depths, High Temperature, High GOR and High
Concentrations of CO2, N2, H2S in Samaria Luna Field

M. Ramirez, ESP OIL AND GAS ENERGY, SA DE CV; J. F. Martinez, PEMEX

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Electric Submersible Pump Symposium held in The Woodlands, Texas, USA, 24-28 April 2017.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
The following study considers the ESP system implementation experience from the year 2009 to 2016 in the
challenging field of Samaria Luna located in the Southern Region of Mexico. During this time frame, many
well failures occurred in the different processes of the ESP system. The study will present a comprehensive
methodology that provides solutions to ultimately extend the run life of wells with ESP system. It will
also discuss the solutions provided to the Samaria Luna project aiming to achieve an acceptable run life
(MTBF) and compare it with international well run life indicators operating under similar field conditions
of temperature, depth, gas, and other adverse conditions for artificial lift systems.
The diagnosis, failure analysis and root cause analysis for the time frame evaluation played an important
role in the construction of the methodology. The results of the evaluation oriented to correction making,
decision making and appropriate optimization strategies in various technical aspects such as: the different
stages of the ESP system, energy quality, equipment maintenance, pump design, pump installation, well
operation and well stabilization. Another important element that will be discussed in the methodology is the
external close supervision from PEMEX to manufacturers and vendors in the field, the office and software
use and application in the different stages of the project.
There are currently not many fields in the world with these characteristics. However, over time artificial
lift systems such as gas lift become inefficient due to an increase in the water cut parameter. For this reason,
in more fields of the world the eventual decision is to transition to ESP as the alternative artificial lift
system due to the advantages of operating in greater depth reservoirs and having much higher volumes of
production.
It is important to share the lessons learnt: optimization strategies, design methodologies, positive and
negative operational practices and other technical actions that have been executed in the Samaria Luna
project that may assist as reference to other fields in the world under similar operating conditions (high
temperature above 280 F, great depths above 12,000 Ft, high GOR above 1500 SCF/STB).
The recommendations of this project may be applied in other projects and directly or indirectly help
improve the run life of wells with ESP system, increasing the project profitability in any part of the world.
2 SPE-185275-MS

History
The Samaria Luna field is located in the south of Mexico, the oil gravity is between 28 and 31 degrees. The
reservoir is naturally fractured with limestone rocks and dolomites from Cetaceous and Jurassic. The total
depth is from 3912 meters to 5100 meters. Gas lift and ESP are the artificial lift system in the field. The
ESP application began in 2009 with many problems explained in the next paper section; finally in 2013
twelve ESP wells were operating.
During 2016 the ESP implementation was reduced due to oil prices. Currently on February 2017 only
one ESP well is operating with 365 run life, but the projection is to install in 2017 several wells applying all
experience (manufacturer and client), learned lections, ESP design improvements, new ESP technologies,
RCA (Root Cause Analysis), power from electrical company direct to the ESP well (no Motor Generator).

DESIGN AND DIAGNOSTIC

The objective of this paper section is show a methodology of diagnostic using software in order to determine
if the ESP pump is working according to manufacturer and client design.
Determine if the ESP pump is working in the optimum range require of many calculations, good technical
evaluation, experience in gassy wells/high temperature/high pump depth in order to determine the pumping
conditions (PIP, Pd, TIP), the fluid properties (Bo, Bg, Bw, viscosity, density, among others), oil, gas and
water production at the intake/discharge head section. The PVT data taken for ESP design no match with the
temperature at the intake section, for this reason it is necessary select the correlations for determining the
correct volumetric factors, density, and viscosity fluid at different temperatures with relation with the PVT.
Additionally, when we do not have PIP, PD, TIP, it is necessary determine the heat transference
coefficients and select the multiphase flow correlations in order to calculate the pressure and temperature
survey above the pump (discharge head) and below the pump (intake section or gas separator), giving as
final result the pump intake pressure (PIP)
For ESP design, the following information is required: Reservoir data and fluids, Mechanical status of
the well, ESP well surface facilities, ESP electrical surface equipment and ESP downhole equipment, Well
production, PI and IPR

Reservoir and fluids data

The required information minimum is perforations depth, static pressure, temperature, however is
necessary the petrophysical information and the well completion: pay zone, effective permeability, relative
permeability, drain ratio, perforation diameter, perforation density, gun type, explosive quantity, phase angle,
gravel pack characteristics, hydraulic fracturing data, among others. The current PI or ESP wells information
around the field is very important. Regarding producing fluids is necessary the PVT data that include the
results of expansion test, constant composition test, differential liberation and separators test.

ESP Well and facilities

When the well is not vertical, we need the survey that include MD, VD, inclination, azimuth and coordinates,
mechanical status, casing length, casing diameters (OD,ID), tubing length, tubing diameters (OD,ID),
perforations depth.
ESP downhole assembly: discharge head depth, pump type and number of stages, gas separator type,
taper pump type, intake section depth, seals configuration and thrust chamber load, ESP motor with the
HP, amperes, volts.

Production well performance

In order to evaluate the production well performance, we need the last production tests of oil, gas, and water
with the operation frequency, choke size, hydraulic parameters from wellhead, Electric parameters from the
SPE-185275-MS 3

generator, step up transformer data, parameters from the VSD, parameters from downhole sensor, chemical
injection data, charts amperes, shut downs record and cause of the stop, production pipe lines diameters.
On the other hand is very important to review the last well services or workover performed during the last
years and the production history with the objective of evaluating tendencies.

DIAGNOSTIC AND DESIGN TECHNICAL CRITERIA

The methodology consists in the review of all the data with validation criteria, analyze the PVT with empiric
correlations, at the same time to find the transference coefficient that match with the surface temperature,
these two validations generate more reliability to calculate the volumetric factors (Bo, Bg, Bw), density and
viscosity, data used for the ESP well design and diagnostic. There are two validation criteria
Validation criteria No. 1: Verify that the oil production (Q bpd), liquid-gas relation GLR scf/stb, tubing
pressure (TP psi), choke size (S_64″) match with the equation of choke performance for Samaria field
(Gilbert, Achong, Ros, etc.).

For applying this criteria is necessary the critic flow thru choke installed in the well, this condition pass
when:

In this last condition, the pressure is in absolute units.

Validation Criteria 2: The second criteria consists in verifying the consistency of the information using
the media calculation of the heat transfer coefficient (U_BTU/hr-ft2-F) from the production tubing and
identifying the fluid flow: Dry Gas and/or condensate, multiphase flow, or only oil and water. The ranges are:

The "U" data incorporate the following heat transference mechanisms: Production tubing and casing
string conduction thru thickness, radiation thru annular space (PT and Casing) and convention, due the well
fluid is in movement. The "U" value represent the total heat flow in BTU/hour circulating thru square foot
of internal thickness per each °F of temperature difference between tubing production fluid and geothermal
temperature around the well.

The U calculation is using Ramsey equation in 1962 (Gas production Operation by Dale Beggs, page
128 OGCI, Tulsa 1984), which this equation allow the production well temperature distribution.
4 SPE-185275-MS

Where:
T: Temperature at vertical depth, °F
Tresv: Reservoir temperature, °F
Ggeot: Geothermal gradient temperature, °F/foot
MPvd: Middle perforations vertical depth
VD: Vertical well depth.
U: Total heat transference coefficient, Btu/hr-ft2-°F
   w: Flow rate weigth, lbm/hr
Cp: Specific heat at constant pressure, Btu / lbm-°F
   d: Internal diameter production tubing, foot
The "U" exact is difficult to calculate, but the adjustment can be performed with the temperatures real
dynamic survey. For example the application PROSPER make the "U" calculations for obtaining the well
head temperature. See in the section: Matching/Matching/VLP/IPR (Quality Check).
The temperature increasing due to heat interchange with the motor Housing, motor stator and fow
passages must be considered in the production tubing temperatures distribution calculations. See M. Power
equation (Paper: "Depth Contraint of Electric Submersible Pumps", SPE PF, May 1994, page 137), Paper
by D. Divine (ESP Course) y by G. Takacs ("Electrical Submersible Pump Manual. Design, Operations,
and Maintenance", page 78)

Where:
ΔT: Fluid temperature increasing, °F
ΔH: Total dynamic head, feet
ηM: ESP Motor efficiency, fraction
ηM: ESP pump efficiency, fraction.
Cp: Specific heat at constant pressure, Btu / lbm-°F
For fast "U" calculations in order to compare with the "U" software calculations, an Excel format (Temp-
RameyESP.xls) was done where the temperature increasing of motor housing is being considered.
SPE-185275-MS 5

In conclusion, for this second criteria the "U" for oil, water and gas wells the "U" is between 4 and 8,
close to 4 when there is a lot of gas and 8 when there is a lot of liquid (GLR less 20sm3/sm3),
For gas and condensate wells the "U" is between 1 and 3, for oil and water wells is between 9 and 12
BTU/hr-ft2°F (Range obtained from PROSPER application "Online help")
All the calculations, application of validation criteria has as main objective to obtain very good models
of well production performance.
After fill all the information in the different section of PROSPER software (PVT, IPR, well survey,
mechanical status, geothermal gradient, down hole and surface ESP assembly, among others).,the next step
is:

PVT analysis and matching

Select the correlations in order to calculate the fluid properties (Pb, Rs, Bo, uo) at different temperature with
respect to reservoir. See PVT/Input Data and fill all information.
6 SPE-185275-MS

Select Match Data and fill the PVT data, is very important to note that the gas solubility (Rs), volumetric
factor (Bo) must be corrected according to separators test. Then select the section Done. Fort he PVT
matching select Regression. Select the section Match All and can see the PVT empiric correlations
available for matching the PVT. Select Acept and then Parameters. Then results
The best correlation for Rs and Bo see in the parameter 1 section where the value is close to one and the
parameter 2 is close to zero in both correlations, in case of having two similar correlations, the option is
select the correlation with less standard deviation. In the same way, the viscosity correlation is selected.
Select the section Done for definitive correlations selection and return to previous menu.
The Green message indicate the PVT match is correct. For example in this ESP well the Lasater
correlation was selected for Pb, Rs, Bo and Beal correlation for Uo. Select Plot to see the graphics and
select variables.
Select the Windows Finish, Done y Done and return to principal menu.

Select representative production tests

Using the validation criteria No 1, review the last production tests (10), be sure that the wells is stabilized
under critic flow condition.
For the criteria application we use the Gilbert equation to obtain the choke size (S) in /64″ compare the
Gilbert calculations with the reported size choke of the field production tests.
If you review the production test taken on July 22, 2015, only in this date both choke size (calculated
and field report) are equal, unfortunately the condition is no critic flow.
However if you review the rest of production tests the choke size calculated is less choke size reported,
this condition is abnormal, the internal wear choke is progressive due to high flow velocity on wellhead.
There are two options to analyze, one of them is possible plugging due to carbonates formation due to high
field salinity and the second option is that the field report is not updated with the right choke sizes.

Wellhead temperature adjustment (WHT)

In order to calculate the fluid properties in the production string, the methodology is make the calculations
for obtaining the total heat transference coefficient and graphic the dynamic temperatures survey in the
production string. Use Ramey equation to calculate the coefficient, which give the quantity the heat flow
between the produced fluid and the wellbore. Use The EXCEL page "Temp-RameyESP.xls to obtain an
initial "U" value and keep as reference and compare with PROSPER application.
SPE-185275-MS 7

To obtain the "U" values in PROPSPER application, fill the good and representative production tests in
the section Matching/Matching/VLP-IPR (Quality Check) and then select the window Estimate U Value
Taking into account the validation criteria No 2, the heat transfer coefficient "U" taken form the
production test performed on October 31, 2015 is 4.877 BTU/hr-ft2-°F, this value is within accepted range
for oil, water and gas wells, this result give reliability in the used information so far. With the production
tests taken before, the coefficient "U" always was less than 4, probably the wellhead temperature on surface
is less than 85°C in these mentioned tests.

Discharge head pressure adjustment

The methodology is to calculate the dynamic pressure gradient survey with different multiphase flow
correlations and select the pressure more close to DP (discharge pressure),then make the corrections to
gravitational component and dynamic gradient friction component, the objective is obtain the exact value
of the discharge head pressure. Prosper application: Select the section Matching/Matching/VLP-IPR
(Quality Check) and then select Correlation Comparison. If all multiphase flow correlations give DP less
than real value (downhole sensor), the option is increase the gas separation efficiency with the objective of
obtain gradient curves above the ESP pump more heavy, otherwise the gas separation efficiency is reduced.
Normally in the manufacturer gas separation information recommend a 90%, but for field studies and
well school test the gas separation efficiency recommended is between 30% and 40%. In this example
40% was taken as total gas separation, the Hadedorn & Brown was selected and adjusted at discharge head
pressure value.
For the PROSPER application select Match VLP for the adjustment, this window belong to Matching/
Matching/VLP-IPR (Quality Check) section. The corrections factors for gravity and friction are 1.02 and
1.00 respectively.

Pump intake pressure matching

Determine the ESP hydraulic losses factor in order to adjust the hydraulic lifting by catalog with respect the
real lifting with the objective of calculating the PIP and compare with the PIP registered by the downhole
sensor.
For making the PIP match is necessary to change the pump wear factor, for example if the factor is 0.1,
this means 10% of hydraulic losses. For this particular case, with the factor zero the PIP match with the
catalog performance.

Well pressure flowing at perforations middle point calculations

With the PIP and using the same multiphase flow correlation, the next step is to calculate the Pwf. Select
Correlation Comparison and then select the correlation in this case (Hagedorn & Brown),final step select
Calculated, OK, you can see the Pwf equal to 117.77 Kg/cm2.

IPR calculations
With the static pressure (Pws), flowing pressure (Pwf) and production test, to calculate the IPR using the
Vogel composite equation. Select the section Matching/Matching/VLP-IPR (Quality Check), then select
VLP/IPR and finally select IPR, be sure that water cut and GOR data is correct, then select Input Data.
The next step is introduce the Pwf = 117.77 Kg/Cm2 select Calculate, finally we obtain the IPR curve.
8 SPE-185275-MS

Return with Finish/Done and select Calculate/Aceptar and Plot, to obtain the well production.

From the graph the calculated well production match with the production field test performed on October
31, 2015.

Quick look
For determine if there is consistence with the information used in the diagnostic, chose the production test,
select the section Quick Look of Matching/Matching/ VLP/IPR. This fast calculation give tubing pressure
(TP), discharge head pressure (DHP), pump intake pressure (PIP), flowing pressure (Pwf) and static pressure
(Pws), then the calculations is repeated in reverse way and both curve must be convergent. Select Quick
Look and updated information with the window Quick Look Data or Input Data, then select Aceptar.
Introduce the amperage and voltage on surface, the horse power calculation equation is :

For I (Amperage)= 68.48 amperes. V (Voltage)= 3150 volts y PF (Power factor)= 0.81 HP= 409 HP.
Select ESP QuickLook and go to Surface Data in order to update I, V, and HP.
SPE-185275-MS 9

The Pump Wear Factor is adjusted in Quick Look, with a consistent PIP the model is updated, select
Transfer Wear Factor, then select Calculate to continue. Select again Calculate, Aceptar and Plot, the
result is the congruency of both curves.

The adjustment in Quick Look was necessary to increase the Pump Wear Factor from 0 to 0.01 (1 %
hydraulic losses), this value was transferred to ESP input data and the Matching/Matching/VLP/IPR.
The pump wear pump was modified, the well flowing pressure (Pwf) is recalculated generating a new IPR,
this calculation is performed in the section Matching/Matching/VLP/IPR, the new well flowing pressure
Pwf = 121.22 Kg/Cm2.
10 SPE-185275-MS

Nodal Analysis
With the representative IPR, the Nodal Analysis technical is used to verify if the ESP pump is working in
the operating range recommended by the manufacturer.
Select the section Calculation/System (Ipr+Vlp)/3 Variable, be sure all information used in the section
Matching/Matching/ VLP/IPR is loaded within IPR Input Data and ESP Input Data, also the multiphase
flow correlations adjusted. Verify all the information is correct and select Continue/Continue/ Calculated
y Aceptar.

Is very important to mention, in the energy balance, the solution node is in the pump discharge head.
Select Solution Details, then select Pump Plot
SPE-185275-MS 11

At 45.5 HZ the ESP pump is working in the efficiency point.

Sensibility analysis: Variation of current and water cut

At frequency more than 55 HZ, the pump is working in severe upthrust. Select Sensitive in Nodal
Analysis results, we can see the impact of the frequency with the oil production at different water cut.
12 SPE-185275-MS

Analysis:
From sensitivity plot the maximum water cut recommended is 90% working at 55 HZ, for water cut over
90% the rentability and economical limit is an factor for being considered.
The ESP well is producing with choke in the wellhead, the recommendation is to include the choke
size, the discharge line to the manifold and reproduce for the oil production the tubing wellhead pressure
calibrating the choke size and the multiphase flow correlation in the surface discharge line.
Under this way the adjustment done with the wellhead tubing pressure (TP) will maintain with the
production test calculated in Matching/Matching, the calculations is in the section Calculation/ Gradient.

ESP System Operation

The operation of an ESP system in wells with high GOR, ultra deep, and high temperature must be monitored
carefully since the design, VSD parameters, start up, frequency changes, rotation, fluid on surface, and well
stabilization. Since 2006 to 2009 several operational problems where identified, some of them were solved,
but in other cases occurred premature failures.

During the operation, the following ítems must be carefully examined:

Power Supply
The energy that powers ESP from a motor generator or central energy must have high quality to avoid
premature failures. If these are not avoided, ESP shut down could impact ESP downhole and surface
integrity.
Samaria field have wells with high temperature that exceed 150 centigrades degrees, if there is an
unexpected ESP shut down and its due to the power supply, the well is shut down, the fluid velocity through
the ESP assembly is zero and there is no cooling, in this moment the motor reaches a maximum temperature
affecting the downhole sensor with operation temperature (140°C maximum), much less than ESP motor
(more than 200°C). In the case of Samaria, this problem occured in several wells, where the sensor stopped
working but the ESP system continues to work without registrating valuable parameters such as: the pump
intake pressure, discharge pressure, motor temperature, pump intake temperature, vibration, current leakage.
These are all very important variables needed for the daily diagnostic and ESP optimization.
SPE-185275-MS 13

Start up
During the start up of the ESP gassy wells, the calculation and adjustment of VSD parameters must be
performed with caution. These parameters include: TAP, V boost, Start HZ, temperature protection, overload
and underload parameters, and initial operation frequency. Due to depth of wells in Samaria field, all these
parameters must be carefully calculate properly and avoid high torques, high temperature, and inverse
rotation. For example, in the current project, we have seen wells with up to four pump (400 series) with an
ESP downhole assembly of 2 motors, 2 seals, 1 gas separator, 1 taper pump, 2 pumps. Due to length of the
shaft, this is very important to take care the high torque, alienation, and temperature.
S-1123 First Baker Run
Start up Date: June 2nd, 2015
Failure Date: August 25th, 2015
Failure due to high temperature intake after two hours and 45 minutes post ignition

Frequency
During the ESP start up, there are multiple frequencies that must be adjusted and controlled in the Variable
Speed Drive. These are: Maximum Operation frequency (MAX HZ), Minimum operation frequency (MIN
HZ), Initial VSD frequency (Start HZ), and ignition frequency (HZ). All these parameters are critical since
the frequency is directly correlate to a complex flow in the cavitation which allows a postiive repsonse in
the operation, and fluid flow. In Samaria, this is even more important due to the low production volumes
betwenn 600 and 1,800 BOPD. An ESP system cannot be waiting for hours to allow fluid because the issues
downhole at high temperature is the main failure mechanism, in particular, the downhole motor and sensor.
S-499 Run No5
Start up date: April 09, 2012
Failure date: December 13, 2013
Run life: 617 days
14 SPE-185275-MS

Variable speed drive and operation mode

For wells with high GOR, high temperature, high pump setting depth, the VSD type and the operation
mode is very important to avoid premature problems during the start up, during the identification of the
ESP rotation, during the time waiting of fluid on surface, during the ESP well stabilization. The operations
modes are: Frequency mode, current mode and PID mode.
During the ESP Project were operational problems with the well stabilization, where the multiphase
flow change, this impact in the wellhead pressure, wellhead choke, more gas production and low oil, in
some cases the frequency is reduced but other parameters as the motor temperature and sensor temperature
increase the values, the operational instability can cause premature failure such as: stuck shaft, broken shaft,
downhole sensor with overheating, ESP motor with overheating and the another potential problem is the
operation in downthrust causing premature pump stages wear
For example, the ESP well S-1123 presented several days with no stabilization, finally the solution was
change the operation mode from Frequency mode to PID mode. On August 20, 2015 the well was operating
with frequency mode and on August 21, 2015 the ESP well was working with PID mode, the solution was
partial.
SPE-185275-MS 15

Chemical downhole injection

The carbonates formation in Samaria Luna field is problem for any production system, the high bottom hole
temperature can affect the chemical injection, therefore fluid sample analysis is recommended to check the
results and improve the chemical formulation if it is necessary. For the ESP system the continue chemical
injection and daily monitoring is very important, to avoid carbonates formation, premature stuck flow
passages pumps or difficulty to restart the ESP operation.
The high bottom well temperature, gas impure, water cut progressive increasing, high pressure drop and
high frequency operation help carbonates formation. For this reason all the ESP stops or shutdown, the
restart is as soon as possible. For ESP wells with long run life, the recommendation is to program a cleaning
pump stages pumping HCL at low concentrations, the result is to improve the TDH, clean the flow passages
and reduce the downthrust effect.

DIAGNOSTIC AND FAILURES ANALYSIS 2009-2014

The purpose of this study is to review all the ESP failures during 2009- 2014 and make the cause root
analysis (RCA), with the objective of applying the results and recommendations for the next years in order
to increase the mean time before failure (MTBF).

ROOT CAUSE ANALYSIS METHODOLOGY

General failures matrix (client and manufacturer)

All the ESP reports 2009-2014 (client and manufacturer) was reviewed in order to prepare a general matrix
and then select by priority the number of wells and the failures for making the root cause analysis (RCA).

ESP wells selected for RCA analysis

The following wells was selected taking into account several technical criteria such as: oil production, water
cut, premature failure, repeated failures, water cut, number of failures, economical limit, current oil price.
Seventeen ESP wells selected with 44 failures.
16 SPE-185275-MS

Root cause analysis results (RCA)

After of making a study the RCA of each failure, the following table presents the RCA results, there are
two wells pending for ESP pulling job, but the preliminary cause of the failure is electrical and mechanical
respectively.

Observing the RCA results, the operational procedures is 30%, manufacture 23%, ESP design 14%,
mechanical stress 9%, well 20%. All this negative results contributed low MTBF (280 days) see Figure……
In conclusion if sum operational procedures +more manufacturer,+ ESP design is more than 65%, very high
percentage attributed to manufacturer and negative for any ESP project.
SPE-185275-MS 17

CONCLUSIONS
▪ According to RCA results, the operational procedures is 30%, manufacture 23%, ESP design 14%,
mechanical stress 9%, well 20%. All this negative results contributed low MTBF (280 days) In
conclusion if sum operational procedures +more manufacturer,+ ESP design is more than 65%, very
high percentage attributed to manufacturer and negative for any ESP project.
▪ The manufacturer experience in gassy ESP wells and the lack of client experience contributed in low
MTBF.
▪ Operational procedures is the major percentage of failure, problems with: start procedure, VSD
parameters settings, cleaning well, power cable manufacturer, splice procedure, ESP running
procedure, chemical downhole injection, tubing torque.
▪ During the study, a low percentage of RCA performed at time by the manufacturer contributed to low
MBTF and generate opportune recommendations for the ESP project.
▪ The ESP manufacture reports and ESP client reports have a lot of technical information, a lot of
pictures but poor engineering analysis.
▪ During the ESP design project, the pumps was oversized, high percentage of pumps were working
in downthrust area, in some ESP wells in severe downthrust.
▪ Lack of manufacturer stock to select more options contributed in premature failures and reduce the
MTB.
▪ Some ESP wells selected in 2009 failed due to high GOR, it was a wrong ESP candidate selection.
The limitation of the ESP system is the gas and work at high GOR relation.
▪ Compression ESP pumps is a very good option in gassy wells, because of the downthrust protection
is better than floating pumps.
▪ In gassy ESP wells and high temperature, the invasion of well fluid to the protector chambers was
premature; the expansion and motor heat transference is very high inside the ESP protector, the
invasion was fast in protector 400 series than 538 series. This affect the ESP motor run life.
▪ The stability and alignment of the downhole ESP equipment was affected by several factors:
ESP design, downthrust, severe downthrust, excessive axial play, excessive radial wear, excessive
vibration, cavitation, material selection for high temperatures, solids no identified, metallic solids
from workover jobs before to install ESP, metallic particles from ESP pump stages, high
temperatures,high GOR, lack of lubrication, ESP wells working with no fluid on surface.
▪ The electric integrity of the ESP system was affected very hard by short circuit, low and unbalance
electrical cable measurements, generator stops, VSD stops, multiples start up, ESP stuck pump, high
torques, carbonates formation inside pump flow passages, bad splice procedure in the field and the
manufacture, capillary tube installation, wrong surface ESP cable installation from junction box to
VSD, power cable handling in the rig, ESP penetrator material, mechanical stress during the cable
running.
▪ The mechanical integrity of the ESP system was affected by broken shafts, shafts with overheating,
stuck shafts, protector thrustbearing destroyed, sleeves destroyed, mechanical seals with wear, ESP
stages with severe wear, in some cases the stages were destroyed.
▪ The operational problem was affected by: frequency setting procedure, VSD protection parameters
settings, VSD with temperature operation limitation, generators stops, multiple starts up. Also
problems with ESP pump working with no fluid on surface, premature downhole sensor failure, fluid
level program, chemical injection tracking, manufacture experience in gassy wells/high temperature/
high depth, choke size operation with ESP gassy wells, ESP right rotation, VSD parameters only
access to the manufacturer, the client only watch the operation.
18 SPE-185275-MS

• The carbonates formation and the chemical injection procedures no continue, affected The run
life of the field, in some wells detected stuck pump, in others wells the chemical injection was
stopped due to problems with capillary tube.
• The poor well cleaning before ESP installation has contributed to the premature ESP failures.
• The downhole sensor failed due to high temperatures. The electronic section have temperature
limitation, the maximum range is 350 °F.
• The RCA (Root Cause Analysis) of ESP Wells were performed not at time, these delay reports
affected the optimization and the correction of the failures for the ESP project.
• The electrical and mechanical failures decreased during the 2015-2016, but the results of
RCA (Root Cause Analysis) of some ESP wells was: incorrect operational procedures and bad
material specificaction for gassy wells and high temperature.

RECOMMENDATIONS
▪ Make an optimum artificial lift system selection according to Samaria Luna reservoir conditions.
▪ Make an optimum ESP design for ESP gassy wells, high temperature and high pump setting depth
using the validation criteria mentioned in the design and diagnostic section of this paper. Avoid
operations with very high GOR, the ESP limitation is the gas and sand.
▪ Make a very good ESP installation and running procedures, avoid mechanical stress of downhole
ESP equipment, capillary tube and power cable, the high temperature and impure gas affect any
mechanical damage. When we take electrical power cable readings without energy is different with
the energized system.
▪ The energy quality is very important in gassy wells in order to avoid shut down, some wells take
many hours or days to reach the stabilization, also in Samaria Luna there is carbonates formation, the
recommendation is restart as soon as possible, avoid stuck or problems to start again.
▪ A very good cleaning well is recommended to avoid stuck in the ESP pump flow passages. The range
of production is between 700 – 1900 BPD with pumps series 400, 540, 538.
▪ Make a good start up procedures considering the multiphase flow changes due to frequency
increasing.
▪ The choke size practices is recommended in gassy wells only to start the pump, avoid the overpressure
on wellhead, this affect the axial load above the shaft ESP system, avoid broken shaft or shaft setting
displacement due to bad choke practices.
▪ Avoid the ESP pump operation in downthrust area in gassy wells and high bottom hole temperature,
the negative effects are: Floating or compression flow passages pumps are affected due to wear
premature, increase the protector axial load over thrust chamber, increase the radial play, the TDH is
reduced, fluid velocity thru ESP motor is less affecting the motor cooling, increase the temperature
of the stages.
▪ Select the materials properly considering the high bottom well temperature, high GOR, impure gas
of Samaria Luna field.
▪ The recommendation is to install AR sleeves in the downhole ESP equipment: protectors, gas
separators, taper pumps, pumps, the abrasion resistant (AR) material help to axial and radial play
protection of the ESP system, reduce the downthrust effect. Avoid the high ESP vibration.
▪ For gassy wells and high temperature the power cable, motor lead extension and surface power cable
must manufactured with lead in each phase. The high temperature and impure gas affects any polymer
material of the cables for ESP application.
▪ Install gas separator and taper pump to reduce the gas into the pump, avoid cavitation.
▪ Review the configuration of the protectors due to high temperature operation of the ESP motors,
mainly when there are stops. The recommendation is to install four protection chambers, mainly in
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assembly series 400 where in wells with high temperature, the heat transference is very high from
the ESP motor to the protector and to the downhole sensor.
▪ Install in Samaria Luna field downhole sensors for tmepartures more than 200 centigrades degrees.
▪ For gassy wells and high temperature, the recommendation is to install penetrator on well head
without splice, without resin, without fast connections, the high temperature, and impure gas affect
the power cable materials. The best option is to pass the downhole power cable direct to junction
box, do not remove any cable material.
▪ Make a good selection of the manufacturer, avoid contracts with very low prices, this affect the results
of the ESP project.
▪ Make a ESP training program to the client, this help the close supervision on the field and having
technical discussions with the manufacturer to optimize the process, increase the MTBF.
▪ Prepare a good ESP reports including technical information and engineering analysis.